Interlocking construction panel showing fabrication thereof and the building system

ABSTRACT

A prefabricated building panel to be used in constructing a building structure includes a generally planar concrete panel one surface and opposite surface also generally planar with a plurality of arrayed hooks couple through an insulation pad opposing hooks of a similar panel mostly mirrored to the first panel providing a cavity space being back filled with a foam insulation providing an lightweight foam core building panel with improved thermal isolation.

FIELD OF THE INVENTION

The invention relates to concrete shapes used in construction or various structures. More particularly, it relates to panels providing walls and finished structures having increased strength over prior art to resist storms and earthquakes. Constructs derived from this building panel have improved thermal and insulation.

BACKGROUND INFORMATION

Concrete blocks of the prior art are conventionally rectangular shapes having cavities extending from top to bottom through the blocks. These cavities are often filled with an insulation material to reduce the heat transfer. Often aligning features have been proposed to assist the workers in laying the block, however these are at an increased cost which makes these aids cost prohibitive and in the end skilled masonry workers prevail. Various mortarless interlocking blocks have been derived to facilitate construction of block walls and structures and the cost to benefit ratio works out so that it also is prohibitive.

Block construction remains very much unchanged; applying mortar and laying block end to end then course on top of course with the set mortar providing the aligning feature to resist the blocks being displaced. When a catastrophe of sufficient forces to overcomes the mass loading and displaces these blocks more than a crack then the effected blocks must be reset or worse fall with crushing force. Much less dramatic shifting of the foundation is the most common reason that a building suffers occasionally a complete loss. The state of the art has shown this block construction to be non-compliant when the acting forces overcome the stiffness, then full recovery is not likely.

While the proposed designs have shown blocks that require less skill to build with them and some even have improved thermal properties none are created by an outer panel and an inner panel joined by hooks insulated between the coupling surfaces. An approximate half pitch vertically staggered course joint is achieved by starting at the base with a half panel and likewise a staggered vertical joint line is achieved. None of the art seen has demonstrated these features.

SUMMARY OF THE INVENTION

The present invention provides a panel having a specialized texture or natural finish planar surface and for special applications the surface might be curved. This generally rectangular surface has a substantially parallel opposite side with hook shaped protrusions with the body extending angularly with a tip segment at right angle to the body and a tip. The panel size determines the quantity, shape and arrangement to consider the load requirement of these hooks. In example, to cast the hooks of small panel because it is difficult to fill small features in a mold it would be preferable to produce them as continuous across the panel.

The panel according to the present invention one method of manufactured will be by casting of concrete in a foam mold. At a manufacturing site a foam mold the rectangular size of the panel to be cast and having the intended hook and rib features created in the upper side is placed on a platen. Removable walls are closely fitted to all sides and extend above the top surface of the foam mold equal to the panel thickness to. This dammed area is filled with concrete level to the top of the walls and vibrated to fill all of the features of the mold. Prior to allow the concrete to set a finish surface or texture is applied. A finished panel is created when wall are removed and the mold material is cleared exposing the hooks. Another method of manufacturing construction panels is using a permanent mold in the mold process.

BRIEF DESCRIPTION OF DRAWINGS

In the annexed drawings:

FIG. 1 shows the inside view of the construction panel

FIG. 2 shows the top view of the construction panel

FIG. 3 shows the side view of the construction panel

FIG. 4 shows a prospective view of the construction panel

FIG. 5 shows an enlarged view

FIG. 6 shows a inside prospective view of a construction panel with door frame and opening

FIG. 7 shows an inside prospective view of a construction panel with window frame and opening

FIG. 8 shows an outside prospective view of a construction panel with attaching features

FIG. 9 shows an inside prospective view of a construction panel with angle faces

FIG. 10 shows an inside prospective view of a construction panel with curved features

FIG. 11 shows a prospective view of the corner post

FIG. 12 shows an inside prospective view of a narrow construction panel

FIG. 13 shows an outside prospective outside view of the construction panel with compartments

FIG. 14 shows the enlarged inside partial view of construction panel with compartments

FIG. 15 shows a side view of joined construction panel

FIG. 16 shows an enlarged partial section view of joined construction panel

FIG. 17 shows an enlarged partial view of the joined construction panel

FIG. 18 shows a plan view of a construction panel in mold base

FIG. 19 shows an exploded side view of a construction panel with mold base

FIG. 20 shows an exploded prospective view of a construction panel with mold base

FIG. 21 shows an enlarged partial inside view of a completed construction panel

FIG. 22 shows a prospective view of the handling tool

FIG. 23 shows another prospective view of the handling tool

FIG. 24 shows a prospective view of the partial structure with handling tool

FIG. 25 shows a partial prospective view of the wall showing bracket

FIG. 26 shows a partial prospective view of the wall showing cleat

FIG. 27 shows a partial prospective view of the wall showing floor bolting

FIG. 28 shows an inside prospective view of a construction panel

FIG. 29 shows an enlarged partial inside view of a completed construction panel

FIG. 30 shows another inside prospective view of a partial structure

FIG. 31 shows the top view of the construction panel

FIG. 32 shows the inside view of the construction panel

FIG. 33 shows the side view of the construction panel

FIG. 34 shows a prospective view of the construction panel

FIG. 35 shows the inside view of the wall

FIG. 36 shows the top view of the wall

FIG. 37 shows the side view of the wall

FIG. 38 shows a prospective view of the wall

DETAILED DESCRIPTION

Referring to the drawings and initially to FIG. 1 there is shown a 1 a basic construction panel according to the invention. This mostly rectangular construction panel has bottom flange 2, top flange 3, and a planar surface 5 opposite a inside surface 6 having connecting features which are arrayed hook 4 protrusions with a hook opening 9 on a plain perpendicular to inside surface 6 and having an engaging surface 10 on the inside of the engaging paw 11. Stiffener ribs 7 are also arrayed on inside surface 6. Construction panels are usually, but not limited to, poured concrete and having a mesh reinforcing 12 of steel. Expanded aggregates and aerated concretes rites are extensively used when casting construction panels. This panel has a panel length 13, a panel width 14 and two thicknesses expressed as, overall thickness 16 over the hook 4 and effective thickness 15 which is approximately half of a finished wall thickness. If required for aesthetic purposes planar surface 5 may be a texture surface 17. Shown in FIG. 6, construction panel 20 configured for a door opening 23 showing the door jab 22 and door header 21.

In FIG. 7 construction panel 30 is configured to a window opening construction panel 30 having usual window opening 33 surrounded by window sill 33, window header 32 and frame 34. Construction panel 40 as shown in FIG. 8 is used to connect walls both exterior and interior through connecting feature 41 as shown to be a tendon. The corner construction panel 50 of this invention is shown in this FIG. 9 whereby the panel is cast having two plane surfaces at angle 52 and inside surfaces 6 are intersected with a fillet 51 to prevent stress rises. Yet another construction panel is demonstrated with curved construction panel 60 having curve 61. A corner post 70 is shown having tendons 71. FIG. 12 shows a reduced width construction panel 80 used primarily to set the stagger of the joints along the wall and for short walls. A composite construction panel 90 is used in FIG. 13 to demonstrate various compartments as, electrical compartment 91, plumbing compartment 92, wall outlet compartment 93 and wall switch compartment 94.

A primary assembly 100 is shown in FIG. 15 when two construction panels are rotated 180 degrees and the hook 4 are nested with paw 11 inserted into hook opening 9 and contacted along surface 101 and thereby bonded 102. FIG. is a partial section through primary assembly 100 while FIG. 17 is an enlarged partial section of primary assembly 100 showing gap 104 provided for fastener entry and cavity 103 to be foam insulation filled.

All construction panels previously shown have been simplified and shown without foam in place. FIG. 18 shows the casting of a construction panel 1 in a mold platen 123 as an assembly 120 with FIG. 19 showing the mold assembly exploded. A foam mold 121 with inserts 122 for demonstration removed from openings in foam mold 121. FIG. 20 is a prospective view of a mold assembly 120.

FIG. 22 is a tool 150 used to place construction panels of all configurations whereby completed construction panel 130 is held in clamp 154 when knobs 155 are screwed inward. The clamp 154 is free to pivot about axis 153 of carriage 156 that is free to move laterally on slides 152 supported by frame 151. Tool 150 has openings on the bottom to provide the entry of a pallet jack or fork truck. FIG. 22 is another view of tool showing complete construction panel 130. Wall stiffness is achiever with joint stagger 329 FIG. 24 is a prospective view of a partial structure 300 showing the above described construction panels in place on footer 302 while FIG. 27 shows construction panels secured to the footer using external threaded fastener 320 extending through bar 322 and clamped by a internal threaded fastener. FIG. 25 is a partial view of the top of the wall shows a bracket with an external threaded fastener extending through a hole and having an internal threaded fastener proving a clamp. Electrical conductors 303 are provided with a construction panel and stored as a service loop 304. Plumbing and air conduit 306 is also provided with construction panel. FIG. 28 is a prospective view of the complete construction panel 130 showing hook 4 and cavity 131 arrayed on inside while FIG. 29 is an enlarged partial view that is rotated slightly for a better view of hook 4 and cavity 131. FIG. 32 shows the inside view of the small construction panel 370, FIG. 31 is a top view while FIG. 33 is a side view. A prospective view is seen with FIG. 34. FIG. 35 is a side view of a partial wall assembly 380 having a course pitch 372 and vertical joints stagger while FIG. 36 is a top view. FIG. 37 is a partial view of a vertical section followed by FIG. 39, a prospective view. 

1. A panel that is useful in the construction of walls for buildings and dwellings that is a rectangular planar face with edges and an opposite face having hook features thereby coupled with hook features of a similar panel enclosing a core cavity producing a core panel with planar faces and has a thickness: a) a planar face with a uniform thickness b) a bottom edge with a flange to connect footer c) a top edge with a flange to connect to upper floor beams or roof truss d) an opposite face with an array of hooks e) a cavity between coupled panels back filled with insulation material f) a cavity between coupled panels back filled with insulation material providing spaces for service conduit g) a planar face with optional decorative surface h) a planar face with provisions for orifice to access service conduit
 2. A panel as in claim 1 wherein said planar face is curved having a vertical axis.
 3. A panel as in claim 1 wherein said planar face is a dihedral with vertical apex.
 4. A panel as in claim 1 wherein said planar face has window feature and header with sill.
 5. A panel as in claim 1 wherein said planar face is a door feature and sills with header.
 6. A panel as in claim 1 wherein said planar face has feature to join wall at right angle.
 7. A panel as in claim 1 wherein said panels are coupled so as having staggered vertical joint.
 8. A panel as in claim 1 wherein coupling features is a dovetail.
 9. A panel as in claim 1 wherein coupling features is a fastener connection.
 10. A panel that is useful in the construction of walls for buildings and dwellings that is a rectangular planar face with edges and an opposite face having hook features thereby coupled with hook features of a similar panel enclosing a core cavity producing a core panel with planar faces and has a thickness: a) a planar face with a uniform thickness b) a bottom edge with a flange c) a top edge with a flange d) an opposite face with an array of hooks e) a cavity between coupled panels back filled with insulation material f) a cavity between coupled panels back filled with insulation material providing spaces for service conduit g) a planar face with optional decorative surface h) a planar face with provisions for orifice to access service conduit
 11. Said panel of claim 10 whereby panels are laid in courses with horizontal and vertical staggered joints.
 12. A panel as in claim 10 wherein said planar face is curved having a vertical axis.
 13. A panel as in claim 10 wherein said planar face is a dihedral with vertical apex.
 14. A panel as in claim 10 wherein said planar face has window feature and header with. sill.
 15. A panel as in claim 10 wherein said planar face is a door feature and sills with header.
 16. A panel as in claim 10 wherein said planar face has feature to join wall at right angle.
 17. A panel as in claim 10 wherein coupling features is a dovetail.
 18. A panel as in claim 10 wherein coupling features is a fastener connection.
 19. A building comprising but not limited to panels shown.
 20. A building comprising of construction panels having inner and outer panel joints staggered
 21. A tool for aligning and placing construction panels 